Interior trim panel with entrapped fasteners

ABSTRACT

A multi-layer laminated trim panel having a first sheet of high density cross-linked polyethylene foam, a second sheet of low density cross-linked polyethylene foam, a plurality of fasteners wherein the fastener heads are entrapped between the first and second sheets of cross-linked polyethylene foam, and an external cover sheet of cloth or vinyl. Additional sheets or pieces of cross-linked polyethylene foam can be incorporated between the first and second sheets of cross-linked polyethylene foam. Various methods of manufacturing the trim panels of the present invention are also disclosed.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates to vehicle trim assemblies and moreparticularly, to multi-layer laminated trim panels having fasteningmeans entrapped between sheets of cross-linked polyethylene foam forattachment to automobile doors, quarter panels, instrument panels,pillars and other interior panels.

Individuals in the market for an automobile consider the aestheticcharacteristics and safety features of the vehicle to be importantfactors in the car buying decision. In response, the automobile industryhas been striving to improve the overall appearance of automobiles,including automobile trim assemblies, while simultaneously enhancing thesafety features. Consequently, thee is a high demand for durable,decorative interior sub-assemblies which can be easily attached tointerior vehicle surfaces and which serve to cushion interior vehiclesurfaces.

It is therefore a primary object of the present invention to provide adurable, decorative trim assembly which can be easily attached tointerior vehicle surfaces and provides vehicle surfaces with enhancedcushioning.

Other advantages and features will become apparent from the followingspecification taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional side view of a two-layer laminated trimpanel incorporating fasteners which are partially embedded within thefirst and second layers.

FIG. 2 is a cross-sectional side view of a two-layer laminated trimpanel incorporating fasteners which are partially embedded within thesecond layer.

FIGS. 3A through 3D are diagrammatic views of various types of fastenerswhich can be utilized with the present invention.

FIG. 4 is a cross-sectional side view of a three-layer laminated trimpanel incorporating fasteners which are partially embedded within thefirst and second layers.

FIG. 5 is a cross-sectional side view of a three-layer laminated trimpanel incorporating fasteners which are partially embedded within thesecond layer.

FIG. 6 is a cross-sectional side view of a two-layer laminated trimpanel incorporating a bun between the first and second layers foradditional padding.

FIG. 7 is a schematic view demonstrating a method of manufacturing theembodiments of FIGS. 1 and 5.

FIG. 8 is a schematic view demonstrating a method of manufacturing theembodiments of FIGS. 2 and 4.

FIG. 9 is a schematic view demonstrating a method of manufacturing theembodiment of FIG. 6.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is illustrated for exemplar purposes embodyingrelatively rectangular shaped multi-layer laminated trim panels. It willbe understood that the multi-layer laminated trim panels can becontoured according to the customer's needs.

The major components of the multi-layer laminated trim panel 10, asshown in FIG. 1, include a first sheet of relatively high densitycross-linked polyethylene foam 20, a second sheet of relatively lowdensity cross-linked polyethylene foam 30 and a plurality of fasteners12 wherein the fastener heads are entrapped between the first and secondsheets of cross-linked polyethylene foam. A third sheet of cross-linkedpolyethylene foam 40 as shown in FIGS. 4 and 5 can also be included.Likewise, one or more buns in FIG. 6 can be incorporated between thefirst and second sheets. Each of the multi-layered trim panelembodiments can be provided with an external covering 50.

Various different types of conventional fasteners 12 can be utilizedwith the present invention as demonstrated by FIGS. 3A through 3D. Thetype of fastener is selected according to the customer's needs. Althoughmany different types of fasteners may be used, it has been determinedthat fasteners having a relatively large flat head are best suited tolimit the foam breakaway values during the manufacturing process and tomaximize ultimate fastening strength.

The present invention resides in the assembly of the trim panel, whichhas fasteners entrapped between first and second sheets of cross-linkedpolyethylene foam 20 and 30, respectively. It has been determined thatfasteners having an elongated flat head are best suited for theinvention. Referring to the embodiments of FIGS. 1 and 2, the trim panel10 includes a first sheet of relatively high density cross-linkedpolyethylene foam 20 having a top surface 24, a bottom surface 26 andone or more side edges 28 depending on the desired shape of the trimpanel. This first sheet of cross-linked polyethylene foam 20 generallyhas a thickness in the range of between about 0.100 and about 0.150inches with a standard thickness of approximately 0.125 inches. For thepurposes of this invention, relatively high density cross-linkedpolyethylene foam is defined as cross-linked polyethylene foam having adensity in the range of between about 10 lbs/ft.³ to about 14 lbs./ft.³.A preferred high density cross-linked polyethylene foam is Huls' brandXJ1200 which has a density of approximately 12 lbs/ft.³.

The first sheet 20 is formed with a plurality of apertures 22 atpreselected locations along the sheet which provide for the attachmentof any one of several different types of mechanical fasteners 12. Uponcomplete insertion into the apertures 22, the fastener heads 14 abut thetop surface 24 of the first sheet 20 and the leading end 18 of thefastener shaft 16 extends beyond the bottom surface 26.

A second sheet of relatively low density cross-linked polyethylene foam30 also includes a top surface 32, a bottom surface 34 and one or moreside edges 36. The second sheet 30 is positioned contiguously upon thefirst sheet 20 such that the bottom surface 34 of this second sheet 30is bonded to the top surface 24 of the first sheet 20, therebyentrapping the fastener heads 14. The second sheet 30 has a generalthickness in the range of between about 0.100 and about 1.500 inches.The thickness of the second sheet 30 is dictated by the customer'sneeds. For example, when the trim panel 10 is to be used on pillars,mainly for decorative purposes, the sheet thickness tends to be about0.125 inches, however, when the trim panel 10 is to be used for sideimpact protection on vehicle doors, the thickness tends to be about1.500 inches. It will be understood that the second sheets' thicknesscan be varied over the course of the sheet to provide the sheet with acontoured appearance. For the purposes of this invention, relatively lowdensity cross-linked polyethylene foam is defined as cross-linkedpolyethylene foam having a density in the range of between about 2lbs./ft³ to about 4 lbs./ft³. Huls' brand XJ200, which has density ofapproximately 2 lbs./ft³ is a preferred brand.

A cover sheet 50 made of a cloth, vinyl or a combination of cloth andvinyl is bonded to the top surface 32 of the second sheet 30 and theside edges 28 and 36 of both the first and second sheets 20 and 30 toprovide the multi-layer laminated trim panel 10 with a decorativeappearance. Milliken 302WCK Textura is a preferred brand of decorativecloth and Haartz 5A is a preferred brand of vinyl. An adhesive orbonding agent may be applied to the top surface 32 and side edges 28 and36 of the second sheet 30 before the cover sheet 50 is bonded to the topsurface 32 for increased adhesion. A film adhesive such as Avery Fastape8706UHA or a spray adhesive such as XR-1305/1375 brand by the H. B.Fuller Co. are preferred brands.

Referring to embodiments of FIGS. 4 and 5, three-layer laminated trimpanels are shown, wherein the second sheet 30 of cross-linkedpolyethylene foam is sandwiched between first and third sheets 20 and40, respectively. In these embodiments, the first sheet is comprised isrelatively high density cross-linked polyethylene foam and the thirdsheet is comprised of relatively low density cross-linked polyethylenefoam as previously described. The second sheet of cross-linkedpolyethylene foam 30 generally has a medium density in the range ofabout 6 lbs./ft³ to about 8 lbs./ft³. Huls' brand XJ600, which has adensity of approximately 6 lbs./ft³ is a preferred brand. The secondsheet 30 is positioned contiguously upon the first sheet 20 such thatthe bottom surface 34 of the second sheet 30 is bonded to the topsurface 24 of the first sheet 20, thereby entrapping the fastener heads14. The third sheet 40 is positioned contiguously upon the second sheet30 such that the bottom surface 44 of the third sheet 40 is bonded tothe top surface 32 of the second sheet 30. A cover sheet 50 is bonded tothe top surface 42 of the third sheet 40 and the side edges 28, 36 and46 of sheets 20, 30 and 40 respectively. Again, it may be desirable toprovide the top surface 42 and side edges 28, 36 and 46 with an adhesivesuch as Avery Fastape 8706UHA or H. B. Fuller Co. brand XR-1305/1375.

Referring to FIG. 6, a trim panel 10 which can be used for side impactprotection includes a first thermoformed sheet of relatively highdensity cross-linked polyethylene foam 20 having a recessed portion 21is shown. The recessed portion 21 houses a piece of cross-linkedpolyethylene, referred to herein as a bun, having a density in the rangeof between about 6 lbs./ft³ to about 8 lbs./ft³. A second sheet ofrelatively low density cross-linked polyethylene foam 30 is positionedupon the first sheet 20 such that the fastener heads 14 are entrappedbetween the first and second sheets 20 and 30 and the bun 31 isentrapped within the recessed portion 21 of first sheet 20 below thesecond sheet 30.

The various multi-layer laminated trim panels 10 can be manufactured asdemonstrated in FIGS. 7, 8, and 9, where like reference numerals areused for similar parts. The embodiments of FIGS. 1 and 5 aremanufactured according to the method demonstrated in FIG. 7. A heatingoven 60 heated to about 300° F. having two separate conveyors 62 and 64which are operable at different speeds is shown. A first sheet ofrelatively high density cross-linked polyethylene foam 20 containingfasteners 12 inserted through apertures 22 is placed upon the firstconveyor 62 which carries the sheet 20 into the oven 60. When this firstsheet 20 reaches a predetermined point within the oven 60, a secondsheet of relatively low density cross-linked polyethylene foam 30 isplaced on the second conveyor 64 which carries it into the oven 60. Themore dense first sheet 20 requires a greater amount of oven exposuretime than the less dense second sheet 30 to become sufficiently tackyfor subsequent chemical bonding of the sheets to occur. The firstconveyor 62 is therefore run at a slower speed than the second conveyor64 so that the first sheet 20 exits the oven 60 just prior to the secondsheet 30.

Once the first sheet 20 has exited the oven 60, the first sheet 20 isplaced in a compression mold press 66 with the fastener heads 14 facingupwardly. Shortly thereafter, while the first sheet 20 is still hot, thesecond sheet 30 is placed contiguously over the first sheet in thecompression mold press 66 as demonstrated by arrows 68 so that thefastener heads 14 are positioned between the first and second sheets 20and 30, respectively. The cover sheet 50 is then positioned over thefirst surface 32 of second sheet 30 and the compression mold press 66 isclosed to cut and form the trim panel 10 to its specified shape andsize. Depending upon the customer's needs, an adhesive may be appliedover the first surface 32 of the second sheet 30 and the side edges ofthe first sheet 20 prior to positioning the cover sheet 50 over thesecond sheet 30. When the compression mold press 66 is closed, thefastener heads 14 become partially recessed into the first surface 26 ofthe first sheet 20 and the second surface 34 of the second sheet 30 dueto the flaccid nature of the first and second sheets 20 and 30. Byrecessing the fastener heads 14, the trim panel 10 obtains structuralrigidity once the trim panel 10 cures.

The embodiment of FIG. 5 is manufactured similarly to the embodiment ofFIG. 1 except that a third sheet of cross-linked polyethylene foam 40,shown in phantom in FIG. 7, is provided. The third sheet of relativelylow density cross-linked polyethylene foam 40 is placed upon the secondconveyor 64 immediately behind the second sheet of medium densitycross-linked polyethylene foam 30. The first sheet of relatively lowdensity cross-linked polyethylene foam 20 is placed in a compressionmold press 66 as it exits the oven 60 with the fastener heads 14 facingupwardly. The second sheet 30 is then placed contiguously over the firstsheet in the compression mold 66 as demonstrated by arrow 68 and thethird sheet 40 is contiguously positioned over the second sheet 30.Cover sheet 50 is then positioned over the first surface 42 of the thirdsheet 40 and the compression mold press 66 is closed to cut and form thetrim panel 10 to its specified shape and size. Again, depending on thecustomer's needs, an adhesive may be applied over the first surface 42of the third sheet 40 and the side edges of the first and second sheets20 and 30 prior to positioning the cover sheet 50 over the third sheet40. When the compression mold press 66 is closed, the fastener heads 14become partially recessed into the top surface 26 of the first sheet 20and the bottom surface 34 of the second sheet 30 due to the flaccidnature of the first and second sheets 20 and 30, respectively.

The multi-layer laminated trim panels 10 of FIGS. 2 and 4 aremanufactured as demonstrated by FIG. 8. The embodiment of FIG. 2 ismanufactured by placing a first sheet of relatively high densitycross-linked polyethylene foam 20 which is at room temperature and hasfasteners 12 inserted through apertures 22 in the compression mold press66 with the fastener heads 14 facing upwardly. A second sheet of mediumdensity cross-linked polyethylene foam 30 is placed on a conveyor 62which carries the second sheet 30 into and through an oven 60 which isheated to about 300° F. The second sheet 30 remains in the oven 60 justlong enough to become sufficiently tacky to bond to both the first sheet20 and the cover sheet 50.

Once through the oven 60, the second sheet 30 is placed contiguouslyupon the first sheet 20 in the compression mold press 66 so that thefastener heads 14 are positioned between the first and second sheets 20and 30, respectively. A cover sheet 50 is then positioned over the topsurface 32 of the second sheet 30 and the compression mold press 66which contains a mold having the three dimensional contour of a finishedpanel is closed, as demonstrated by arrows 68, to cut and form the trimpanel to its specified shape and size. Here again, depending upon thecustomer's needs, an adhesive may be applied over the first surface 32of the second sheet 30 and the side edges of the first sheet 20 prior topositioning the cover sheet 50 over the second sheet 30. The fastenerheads 14 become recessed within the second sheet 30 due to the flaccidnature of the second sheet 30.

The embodiment of FIG. 4 is manufactured similarly to the embodiment ofFIG. 2, except that a third sheet of cross-linked polyethylene foam 40,shown in phantom in FIG. 8, is provided. The third sheet of relativelylow density cross-linked polyethylene foam 40 is placed upon theconveyor 62 just behind the second sheet of medium density cross-linkedpolyethylene foam 30. Once through the oven 60, which is heated to 300°F., the second sheet 30 is placed contiguously upon the first sheet inthe compression mold 66 so that the fastener heads 14 are positionedbetween the first and second sheets 20 and 30, respectively. The thirdsheet 40 is then positioned over the top surface 32 of the second sheet30 and a cover sheet 50 is placed over the top surface 42 of the thirdsheet 40. It may be desirable to apply an adhesive over the top surface42 of the third sheet 40 and the side edges of the first and secondsheets 20 and 30 prior to positioning the cover sheet 50 over the topsurface 42. Compression mold 66 which contains a mold having the threedimensional contour of the finished panel is then closed, asdemonstrated by arrow 68 to cut and form the trim panel to its specifyshape and size. During compression in the compression mold, the fastenerheads 14 become recessed within the second sheet 30 due to the flaccidnature of the second sheet 30.

The embodiment of FIG. 6 is manufactured as demonstrated by FIG. 9. Thefirst sheet of thermoformed high density cross-linked polyethylene foam20 which is at room temperature and has fasteners 12 inserted throughapertures 22 is placed in the compression mold press 66 with thefastener heads 14 facing upwardly. A bun 31 made of medium densitycross-linked polyethylene foam is placed within the recessed portion 21of the first sheet 20 within the compression mold press 66. A secondsheet of relatively low density cross-linked polyethylene foam 30 isplaced on a conveyor 62 which carries the second sheet 30 into andthrough an oven 60 which is heated to about 300° F. The second sheet 30remains in the oven 60 long enough to become sufficiently tacky to bondto both the first surface 22 of the first sheet 20, the top surface 33of the bun 31 and the cover sheet 50.

Once through the oven 60, the second sheet 30 is placed contiguouslyupon the first sheet 20 and over the bun 31 in the compression moldpress 66 so that the fastener heads 14 are positioned between the firstand second sheets 20 and 30, respectively. A cover sheet 50 is thenpositioned over the top surface 32 of the second sheet 30 and thecompression mold press 66 which contains a mold having the threedimensional contour of a finished panel is closed, as demonstrated byarrows 68 to cut and form the trim panel 10 to its specified shape andsize. It may once again be desirable to apply an adhesive over the topsurface 32 and side edges of the first sheet 30 and bun 31 prior topositioning the cover sheet 50 over the top surface 32. The fastenerheads 14 become recessed within the second sheet 30 due to the flaccidnature of the second sheet 30.

While it will be apparent that the preferred embodiment of the inventiondisclosed are well calculated to provide the advantages above stated, itwill be appreciated that the invention is susceptible to modification,variation and change without department from the proper scope or fairmeaning of the subjoined claims.

What is claimed:
 1. A multi-layer laminated trim panel for attachment tovehicles, comprising:(a) a first sheet of high density polymeric foamdefined by first and second surfaces, said first sheet having aplurality of apertures therethrough; (b) fastening means defined by ahead and an extending shaft, wherein the shaft of said fastening meansis inserted into said first sheet apertures to partially extend beyondthe second surface of said first sheet; and (c) a second sheet of lowdensity polymeric foam defined by first and second surfaces wherein afirst surface of said first sheet is bonded to a first surface of saidsecond sheet entrapping the head of said fastening means.
 2. Amulti-layer laminated trim panel as claimed in claim 1, wherein saidfirst and second polymeric foam sheets further comprise cross-linkedpolyethylene foam.
 3. A multi-layer laminated trim panel as claimed inclaim 1, wherein a cover sheet is bonded to the second surface of saidsecond sheet, said cover sheet wrapping substantially around said firstand second sheets.
 4. A multi-layer laminated trim panel as claimed inclaim 3, wherein said cover sheet consists of a material selected fromthe group consisting of cloth, vinyl and combinations thereof.
 5. Amulti-layer laminated trim panel as claimed in claim 1, wherein the headof said fastening means is partially recessed within said second sheetof polymeric foam.
 6. A multi-layer laminated trim panel as claimed inclaim 5, wherein the head of said fastening means is partially recessedwithin said first sheet of polymeric foam.
 7. A multi-layer laminatedtrim panel as claimed in claim 5, wherein the head of said fasteningmeans is substantially flat.
 8. A multi-layer laminated trim panel asclaimed in claim 1, wherein said fastening means comprises a heat stake.9. A multi-layer laminated trim panel as claimed in claim 1, whereinsaid fastening means comprises metal.
 10. A multi-layer laminated trimpanel as claimed in claim 1, wherein said first sheet of high densitypolymeric foam has a density of between about 10 lbs./ft³ to about 14lbs./ft.³.
 11. A multi-layer laminated trim panel as claimed in claim10, wherein said first sheet of high density polymeric foam has adensity of about 12 lbs./ft³.
 12. A multi-layer laminated trim panel asclaimed in claim 1, wherein said second sheet of low density polymericfoam has a density of between about 2 lb./ft.³ to about 4 lbs./ft.³. 13.A multi-layer laminated trim panel as claimed in claim 12, wherein saidsecond sheet of low density polymeric foam has a density of about 2lbs./ft.³.
 14. A multi-layer laminated trim panel as claimed in claim 1,wherein said first sheet of high density polymeric foam has a thicknessof between about 0.100 and about 0.150 inches.
 15. A multi-layerlaminated trim panel as claimed in claim 1, wherein said second sheet oflow density polymeric foam has a thickness of between about 0.100 toabout 1.500 inches.
 16. A multi-layer laminated trim panel as claimed inclaim 1, wherein a third sheet of polymeric foam defined by first andsecond surfaces is provided wherein the first surface of said thirdsheet is bonded to a second surface of said second sheet.
 17. Amulti-layer laminated trim panel as claimed in claim 16, wherein saidthird sheet further comprises cross-linked polyethylene foam.
 18. Amulti-layer laminated trim panel as claimed in claim 16, wherein a coversheet is bonded to the second surface of said third sheet, said coversheet wrapping substantially around said first, second and third sheets.19. A multi-layer laminated trim panel as claimed in claim 18, whereinthe head of said fastening means is partially recessed within saidsecond sheet of polymeric foam.
 20. A multi-layer laminated trim panelas claimed in claim 19, wherein the head of said fastening means ispartially recessed within said first sheet of polymeric foam.
 21. Amulti-layer laminated trim panel as claimed in claim 19, wherein thehead of said fastening means is substantially flat.
 22. A multi-layerlaminated trim panel as claimed in claim 18, wherein said cover sheetconsists of a material selected from the group consisting of cloth,vinyl and combinations thereof.
 23. A multi-layer laminated trim panelas claimed in claim 1, wherein at least one bun of polymeric foam isprovided between said first and second sheets of polymeric foam.
 24. Amulti-layer laminated trim panel as claimed in claim 23, wherein a coversheet is bonded to the second surface of said second sheet, said coversheet wrapping substantially around said first and second sheets.
 25. Amulti-layer laminated trim panel as claimed in claim 24, wherein a coversheet is bonded to the second surface of said second sheet, said coversheet wrapping substantially around said first and second sheets.
 26. Amulti-layer laminated trim panel as claimed in claim 23, wherein thehead of said fastening means is partially recessed within said secondsheet of polymeric foam.
 27. A multi-layer laminated trim panel asclaimed in claim 26, wherein the head of said fastening means ispartially recessed within said first sheet of polymeric foam.
 28. Amulti-layer laminated trim panel as claimed in claim 27, wherein thehead of said fastening means is substantially flat.
 29. A multi-layerlaminated trim panel as claimed in claim 23, wherein said at least onebun has a density of between about 6 lbs./ft³ to about 8 lbs./ft³.
 30. Amulti-layer laminated trim panel as claimed in claim 29, wherein said atleast one bun has a density of about 6 lbs. /ft³.
 31. A multi-layerlaminated trim panel as claimed in claim 23, wherein said at least onebun has a thickness of up to 2.0 inches.